Method of furniture construction



3 Sheets-Sheet 1 INVENTOR DAVID T. ARMSTRONG D. T. ARMSTRONG METHOD OF FURNITURE CONSTRUCTION Oct. 10, 1967 Original Filed Feb. 20, 1964 ATTORNEY D. T- ARMSTRONG METHOD OF FURNITURE CONSTRUCTION Oct. 10, 1967 3 Sheets-Sheet 2 Original Filed Feb. 20, 1964 INVENTOR DAVID T. ARMSTRONG ATTORNEY United States Patent 3,345,720 METHOD OF FURNITURE CONSTRUCTION David T. Armstrong, Canton, Miss. 39046 Original application Feb. 20, 1964, Ser. No. 346,308, now Patent No. 3,256,041, dated June 14, 1966. Divided and this application Apr. 11, 1966, Ser. No. 568,075

6 Claims. (Cl. 2991.1)

ABSTRACT OF THE DISCLOSURE A method of constructing furniture in which interior frame members are positioned unbonded to each other in -a form which defines a desired configuration, an exterior skin cut to the desired configuration is placed on the upper edges of the positioned frame members and then bonded thereto, using a plate applied to the exposed face of the skin during the bonding operation, in conjunction with bonding means which include adhesive applied to the upper edges of the frame members, thereby also fixing the frame members in fixed immovable relationship to each other.

This application is a division of prior copending application Ser. No. 346,308, filed Feb. 20-, 1964, now U.S. Patent 3,256,041, issued June 14, 1966.

This invention relates to a method of making upholstered furniture. More particularly, this invention relates to a method for forming arm structures, wing structures, and other parts for upholstered chairs, couches and the like.

In conventional upholstered furniture arm and frame construction, heavy frame members are first assembled and fastened together as by doweling, nailing or the like, in order to support the frame. In most instances it is necessary to saw or shape curves or other intricate designs on top arm frame members. In order to upholster conventional frame construction, it is necessary to add coverings to the frame, such as chipboard, burlap, etc., in order to support the padding and/ or upholstering fabric which is stretched over the chipboard, burlap, etc., and tacked or stapled to tack strips positioned at various points in the frame. Because of the high cost of labor and material and the growing competition in the upholstering furniture manufacturing business, it has become imperative that new methods and techniques of manufacturing upholstered furniture be devised in order to reduce the number of parts, fasteners and material in the furniture and to also reduce the cost of labor required for assembly.

Accordingly, it is an object of this invention to provide a method of constructing upholstered furniture whereby the need for doweling or nailing, or otherwise fastening interior frame members is eliminated.

Another object of this invention is to provide a method of constructing upholstered furniture frames, wherein the use of an inner covering such as chipboard or burlap or the like for supporting the outer upholstering fabric is eliminated.

A further object of this invention is to provide a method of constructing upholstered furniture wherein exterior skin members of masonite, plywood or other laminated material is directly glued or stapled to interior frame members, thereby not only reducing the number of interior frame members required, but also permitting the interior frame members to be directly glued or stapled to the exterior skin.

Another object of this invention is to provide a method of constructing upholstered furniture utilizing exterior skin directly attached to interior frame members, thereby permitting exterior upholstering fabric to be tacked, stapled, glued or otherwise fastened directly to the exterior skin and thus eliminating the need for extra interior frame 3,345,720 Patented Oct. 10, 1957 members and tack strips normally required to provide stapling support in conventional upholstered frame structure.

Still another object of this invention is to provide a method of constructing upholstered furniture utilizing exterior skin wherein a stronger structure of more accurate and exact profile is provided.

Still another object of this invention is to provide a method of constructing upholstered frame furniture wherein interior frame parts are first positioned in a form and then directly glued to exterior skins on opposite sides.

These and many other objects may be achieved in accordance with the method of this invention which in general may include the steps of positioning the interior members comprising the frame in a suitable form, applying glue or other adhesive to an edge of the parts positioned in the form; cutting an exterior skin member to the desired profile corresponding to the interior frame; positioning said exterior skin on the glued edges of said interior frame members; placing a stencil corresponding to the position of the interior frame members of said frame on said exterior skin; and attaching said exterior skin to said interior frame members by means of suitable fasteners utilizing said stencil. The skin on the opposite side of the frame is similarly secured to the frame by turning the assembly over; applying glue to the exposed edges of the interior frame members; placing a second skin cut to the desired profile on said glued exterior edges; placing a similar stencil on said second skin; and fastening said second skin to said interior frame as by stapling or nailing, utilizing said stencil placed thereon.

Apparatus for practicing the method of skin construction in upholstered furniture may in general include a first form comprising upright stops arranged in a determined configuration to form an interior profile, said first form being of sufiicient depth to receive said interior members; a stencil having cut-out portions corresponding to the configuration formed by said interior frame members when positioned in said first form hingedly secured to said first form; a second form corresponding to the configuration of the interior frame members as positioned in said first form, positioned adjacent said first form; and a second stencil similar in configuration to said first stencil, pivotally secured to said second form.

These and many other objects and advantages of this invention will become more readily apparent from the following detailed description when read in View of the appended drawings wherein:

FIGURE 1 is a plan view of forms and stencils in accordance with the principles of this invention;

FIGURE 2 is a sectional view taken along the lines 22 of FIGURE 1, illustrating the interior of the forms in greater detail;

FIGURE 3 is an end view of the form illustrating the manner in which the stencils are pivotally secured to the form;

FIGURE 4 illustrates the heavy framing construction of conventional upholstered frame construction;

FIGURE 5 illustrates a chair-arm construction in accordance with the skin-type construction of this invention;

...-FIGURE 6 further illustrates the conventional heavy frame construction in upholstered wing-back type of chair; and

FIGURE 7 illustrates a wing-back chair constructed in accordance with the skin-type structure of this invention.

Referring now to the drawings, FIGURES 1 through 3 illustrate a preferred embodiment of an apparatus for practicing this invention and which in general includes adjacent molds or forms 11 and 12 of wood, metal, plastic or other suitable material, to which are attached as by means of hinges 13 suitable stencils 14 and 16, respectively. In the arrangement shown, the forms 11 and 12 are arranged for the assembly of upholstered chair arms although, as will become apparent, forms for producing any portion of an upholstered chair, sofa, couch or the like may be provided utilizing the principles of this invention.

The form 11 is provided with a suitable cavity 17 of sufficient depth to receive stop members 18 positioned on edge and arranged within the cavity 17 in the desired configuration. As noted in thi instance the stops 18 are arranged to form a chair arm. Frame members 19 of the chair arm are-then positioned on edge within the cavity between the stops 18. The interior frame members 19 may be arranged to engage one another so as to provide a continuous exterior or certain of the frame members 19 may be foreshortened and spaced from adjacent frame members as designated by the reference numeral 21. The number, size and shape of the interior frame members are of course variable and determine the configuration and profile of the structure to be formed.

The form 12 is provided with a cavity 22 of the same depth as the cavity 17 and is positioned adjacent the form 11. No stop members 18 are utilized in the cavity 22in the form 12 and the cavity 22 conforms in configuration to the outside members of the interior frame members 19 as arranged within the form 11.

The stencils 14 and 16 may be formed of sheet metal plastic, plywood or the like, and are pivotally attached to the forms 11 and 12, respectively, by hinges 15. Both stencils include cut-out portions 23 corresponding in position to the location of the interior frame members 19 and 21 as positioned between the stops 18 in the form 11. The cut-out portions 23 of the stencils 14 and 16 form a pattern that corresponds in configuration to the exterior of the armchair structure as determined by the interior frame members 19.

In practice, the construction of a typical skin frame using a form and stencil in accordance with this invention is as follows. The interior frame parts 19 are placed on edge in the form 11 between the stops 18 and then glue or other suitable adhesive is applied to the upper exposed edges of the members 19. A sheet of masonite, plywood or other similar hardboard or lamination which has been cut to the exact outline of the desired overall frame is then laid over the form and pressed onto the glued edges of the members 19. The stencil 14 is then swung into position and laid directly on the exterior skin now glued to the interior frame members. As the cut-out portions 23 of the stencil 14 correspond in position to the location of the interior frame members 19 under the skin, the skin is then readily stapled or nailed or otherwise fastened directly to the interior frame members 19 by driving nails or staples into the skin through the cut-out portions 23 in the stencil 14. Having nailed or stapled at spaced intervals completely around the configuration of the interior frame within the cut-out portions 23, the stencil 14 is then raised and the entire frame with one side having a skin attached thereto is turned end-for-end and upside down and placed in the adjacent form 22. As the first skin supports the interior frame members 19 in the desired position, no stops 18 are required in the cavity 22 in the form 12. The exposed upper edges of the interior frame members 19 are then covered with glue or suitable adhesive and a second skin placed over them in the form 12. The stencil 16 is then swung into position over the second skin which is stapled or nailed, or otherwise fastened to the interior frame members 19. The stencil 16 is then raised and the completed chair arm section, both sides having been skinned, removed from the form 12. The desired upholstering fabric may then be tacked or stapled directly to the exterior skin of the chair arm, thereby eliminating the use of chipboard or burlap as in conventional upholstered construction. There is no need to stretch any other supporting material over the frame at a later stage of the upholstery operation, and the chair arm may now be directly assembled into the completed chair.

Thus the invention provides a method of and apparatus for constructing upholstered furniture that provides numerous advantages and features over the conventional upholstered furniture construction. An important feature of the skin frame construction of this invention is that it eliminates the need for doweling, nailing or otherwise fastening interior frame members to each other, as it is merely necessary to position interior frame members 19 within the form 11. Both exterior skins may then be glued and stapled directly to the interior frame members to provide an exceptionally strong structure requiring a minimum use of interior parts and fasteners.

Interior frame pieces can be located within the skins wherever mechanisms (such as for recliners, sofa beds, etc.) are to be mounted and can be so arranged as to provide direct transmission of the load through said interior members to main peripheral members and so to the floor. (Part 29 in FIG. 5 is such a member.)

Basically, the strength and rigidity of this type construction is obtained from the skin itself. The interior wood members to which the skin is fastened perevent the skin from buckling as it would due to columnar effect if a load were applied in a vertical direction to an unsupported skin. The skin also eliminates the need for diagonal bracing (i.e., corner blocks) between interior frame members because of the inherent strength and rigidity of the skin in the plane of the skin.

Further, the necessity of sawing or shaping curves or other intricate designs on top arm frame members is reduced or eliminated as short scrap pieces can be utilized to form the interior frame and to approximate the desired curves with little loss of strength by using the exterior skin. In addition, the use of exterior skins provides more accuracy and exactness of profile of the finished chair arm as the inaccuracies introduced by variable tolerances between the multiple interfitting pieces of conventional frame construction is eliminated.

Another important saving is the elimination of extra interior frame members such as tack strips for providing stapling support, as in the conventional construction, because in utilizing the skin construction technique the exterior skin alone holds the necessary staples. And, of course, by eliminating the number of parts required, the number of fasteners to be installed, the manufacturing time and thus cost is decreased. In accordance with the invention, the interior frame parts are simply positioned within the form, spread with glue and the exterior skin stapled down on the interior frame members. This provides a great savings in manufacturing costs.

A primary advantage of upholstered furniture constructed in accordance with the principles of this invention is that the size and number of interior frame members are greatly reduced and the use of dowels, screws and other fasteners for securing the interior frame members together is eliminated. This results in a great savings. A conventional upholstered chair arm frame structure is illustrated in FIGURE 4, while a similar chair arm construction in accordance with the principles of this invention, is illustrated in FIGURE 5. Having formed the chair arm construction of FIGURE 4 by fastening the various frame members together as by screws 24, it is then necessary to staple or tack a chipboard covering or burlap 25 to the frame in order to support the upholstering fabric 25' which is stretched over the frame.

It also should be noted that the upper curved rail of the chair arm construction as shown in FIGURE 4 is formed of ane solid piece that has been sawed or otherwise shaped to the desired curvature. Note also in FIGURE 4, the use of a second continuous and heavy interior rail 27 in the conventional structure shown in FIGURE 4 and the corner wedges or braces 20, which are necessary to provide a strong supporting frame.

Referring to FIGURE 5, the advantages of the skin construction technique in accordance with this invention become readily apparent when compared to the conventional practice as illustrated in FIGURE 4. Because of i the great strength added by the exterior skin 28, the requirement of a single continuous interior rail 27, as in FIGURE 4, is eliminated and a shortened rail 29 is all that is required. Of particular importance is the fact that by utilizing the skin construction technique, the necessity of using a single curved upper rail in a chair arm is eliminated, that is, it is possible using the skin construction to utilize shortened scraps of material 31 positioned so as to approximate the desired curvature of the finished arm. The exterior skins are cut to the desired profile and the sections 31 are glued and stapled directly to the exterior skin. This construction not only provides a more exact profile and eliminates the use of fasteners but provides greater strength than the conventional chair arm construction as shown in FIGURE 4.

Referring now to FIGURE 6, a conventional upholstered chair having a wingback is illustrated, while FIG- URE 7 illustrates a similar wingback chair in accordance with the skin-type construction of this invention. As already stated, it is necessary using conventional upholstered furniture assembly techniques that all of the heavy interior frame members 'be fastened together as by doweling or by means of screws or other suitable fasteners and it should be further noted that in general, exceptionally heavy, wide, upper and lower chair rails 36 and 37 must be used in order to provide strength and also the necessary tacking surface for stapling or tacking the numerous coverings of chipboard and burlap 40 prior to stretching the upholstering fabric 40' over the frame. In addition, a third heavy interior rail 38 is required in conventional structures. In order to form the wingback itself, exceptionally heavy form members 39 are necessary again to provide the excessively large tacking and stapling surface required in order to apply the numerous coverings of burlap 40 prior to stretching the exterior upholstering fabric 40' over the wingback frame.

The advantages of the skin-type construction in accordance with this invention in assembling wingback chairs are clearly demonstrated by FIGURE 7. As already described the use of exterior skins on both sides of the frame not only provides exceptional strength, but it eliminates the use of numerous interior parts and fasteners because interior fasteners are not required and because the upholstering fabric can be stapled or nailed directly to the exterior skin, thus eliminating the requirement for excessive interior stapling surfaces. As shown in FIGURE 7, the rails 36 and 38 of FIGURE 6 are completely eliminated and the bottom rail 41 of the chair illustrated in FIGURE 7 is greatly reduced in size. The use of exterior skins 42 in the arm frame and wings of the chair as illustrated in FIGURE 7 is of great advantage not only because it greatly reduces the size of the interior members 43 forming the wing compared to the members 39 of FIGURE 6, but because it greatly reduces the time for assembly. The tedious time-consuming operations of stretching one or more layers of burlap over the curved Wing surfaces is eliminated and a much stronger wing is provided. Further, the wing sections themselves can be preformed if desired. Having completed the skin construction, the exterior upholstering fabric 44 may then be di rectly stapled or tacked to the exterior skins 42 of the wings and the chair arms.

Although a preferred embodiment of the invention has been described in detail, numerous modifications and changes can be made within the principles of the invention which is to be limited only by the scope of the appended claims.

What is claimed is:

1. The method of making an upholstered furniture comprising the steps of:

making a first form corresponding in configuration to the furniture structure to be made; placing interior frame members in said form; applying adhesive to said interior frame members; placing an exterior skin over said interior frame members; placing a stencil over said exterior skin, said stencil having cut-out portions corresponding to the position of said interior frame members under said skin; fastening said exterior skin to said interior frame members through said cut-out portions in said stencil; inverting and positioning said assembly in a second form corresponding in configuration to said first form, exterior skin side down; applying adhesive to the exposed edges of said interior frame members; placing a second exterior skin over said interior frame members; placing a stencil over said second skin, said stencil including cut-out portions corresponding to the position of said interior frame members; and fastening said second skin to said interior frame members through said cut-out portions in said stencil. 2. The method of claim 1 wherein said first and second exterior skins are stapled to said interior frame members. 3. The method of claim 1 wherein said exterior skin members are nailed to said interior frame members.

4. The method of making a furniture structure comprising the steps of:

making a form corresponding in configuration to the furniture structure to be made; placing interior frame members in said form in unbonded but immovable relationship to each other, at least a portion of said interior frame members defining the outline of said configuration; bonding a first exterior skin cut to correspond in configuration to said furniture structure, to the upper edges of said interior frame members in configuration conforming relationship therewith While said interior frame members are in said form; removing the assembly of interior frame members and exterior skin bonded thereto; and bonding a second exterior skin, cut to correspond in configuration to said furniture structure, to the exposed edges of the interior frame members in configuration conforming relationship therewith, thereby fixing said interior frame members in rigid immovable relationship to each other. 5. The method of making a furniture structure comprising the steps of:

making a form corresponding in configuration to the furniture structure to be made; placing interior frame members in said form in unbonded but immovable relationship to each other, at least a portion of said interior frame members defining the outline of said configuration; cutting an exterior skin member so as to correspond in configuration to said furniture structure; placing said exterior skin over said frame members in configuration conforming relationship therewith; bonding said exterior skin to the upper edges of said interior members by means comprising a plate, applied during the bonding step to the exposed face of said skin, used in combination with fastening means which include adhesive applied to the upper edges of said interior frame members in contact with said exterior skin, thereby also fixing said interior frame members in rigid immovable relationship to each other. 6. Method as defined in claim 5 including the steps of: inverting the assembly of interior frame members to which the exterior skin is bonded; applying adhesive to the exposed upper edges of said interior frame members; cutting a second exterior skin so as to correspond in configuration to said furniture structure;

7 8 placing said second exterior over said frame members 2,369,960 2/1945 Gage et a1. 29407 X in configuration conforming relationship therewith; 2 705 995 4 1 55 McMur/[y 29 4 bo di n said second exterior skin to said frame mem- 2913041 11/1959 Mathison 29 91'1 g 3,094,716 6/1963 Friedman 156229 bers in the same manner in which the first exterior 5 skin Was bonded thereto.

JOHN F. CAMPBELL, Primary Examiner.

References Cited THOMAS M. EAGER, Assistant Examiner.

UNITED STATES PATENTS 911,376 2/1909 Buser 2991.7 10 

1. THE METHOD OF MAKING AN UPHOLSTERED FURNITURE COMPRISING THE STEPS OF: MAKING A FIRST FORM CORRESPONDING IN CONFIGURATION TO THE FURNITURE STRUCTURE TO BE MADE; PLACING INTERIOR FRAME MEMBERS IN SAID FORM; APPLYING ADHESIVE TO SAID INTERIOR FRAME MEMBERS; PLACING AN EXTERIOR SKIN OVER SAID INTERIOR FRAME MEMBERS; PLACING A STENCIL OVER SAID EXTERIOR SKIN, SAID STENCIL HAVING CUT-OUT PORTIONS CORRESPONDING TO THE POSITION OF SAID INTERIOR FRAME MEMBERS UNDER SAID SKIN; FASTENING SAID EXTERIOR SKIN TO SAID INTERIOR FRAME MEMBERS THROUGH SAID CUT-OUT PORTIONS IN SAID STENCIL; 